Abstract: A battery includes positive and negative current collectors and a plurality of bipolar electrodes arranged in a stack between the positive and negative current collectors. The positive and negative current collectors and the stack of the plurality of bipolar electrodes are folded in an S-shape.

Abstract: In various aspects, the present disclosure provides solvent-free methods of making a solid-state electrode active layer for a solid-state electrode in an electrochemical cell that cycles lithium ions, by using a plurality of solid polymeric binder particles capable of fibrillation with porous fibrillation particles with a first shear force to at least partially fibrillate the solid polymeric binder particles to form a polymeric binder mixture. The disclosure also contemplates a current collector and a porous active layer disposed thereon. The porous active layer includes a fibrous polymeric network having a plurality of solid particles distributed therein. The solid particles may include electroactive material particles, solid-state electrolyte particles, and porous fibrillation particles.

Abstract: A bipolar battery includes N battery cores each comprising a cathode electrode, an anode electrode, and a separator, where N is an integer greater than one. N?1 bipolar plates include a first layer made of a first material, a second layer made of a second material, a center portion, and first and second sides extending transversely relative to the center portion. A battery enclosure including a cover and a lower portion including sides defining a cavity. The N?1 bipolar plates are arranged in the cavity between adjacent ones of the N battery cores and the N battery cores are connected in series by the N?1 bipolar plates. The first and second sides of the N?1 bipolar plates are one of inserted into “L”-shaped slots in the sides of the lower portion, and molded into the sides of the lower portion.

Abstract: A bipolar solid-state battery includes N solid-state battery cells. Each of the N solid-state battery cells includes M solid-state cores each comprising a first current collector, cathode active material, a separator, anode active material, and a second current collector, where N and M are integers greater than one. The M solid-state cores are connected in parallel by connecting the first current collectors of the M solid-state cores in each of the N solid-state battery cells together and by connecting the second current collectors of the M solid-state cores in each of the N solid-state battery cells together. N?1 clad plates including a first side made of a first material and a second side made of a second material. The N?1 clad plates are arranged between adjacent ones of the N solid-state battery cells and the N solid-state battery cells are connected in series by the N?1 clad plates.

Abstract: A battery cell includes a continuous anode electrode comprising an anode current collector. A plurality of individual cathode electrodes include a cathode current collector, cathode active material arranged on opposite sides of the cathode current collector, and a first sulfide electrolyte layer arranged on the cathode active material. The continuous anode electrode is arranged in a zig-zag pattern and the plurality of individual cathode electrodes are arranged between adjacent alternating portions of the continuous anode electrode.

Abstract: A bipolar battery cell includes a stack including N current collectors, M anode electrodes, S separators, and C cathode electrodes, where N, M, S and C are integers greater than one. A first positioning member is arranged on one side of the stack and includes a first planar portion and a first slot in the first planar portion. A first one of the C current collectors extends through the first slot in the first planar portion and is folded. The first positioning member further includes a first rail portion and a second rail portion. The first rail portion and the second rail portion extend from the first planar portion. A first external tab is arranged between the first rail portion and the second rail portion and connected to the first one of the C current collectors.

Abstract: An electrode assembly for an electrochemical cell that cycles lithium ions is provided. The electrode assembly includes one or more electroactive material layers including a plurality of electroactive material particles and a plurality of binder material fibers dispersed with the electroactive material particles. At least one electroactive material particle of the plurality may have a first protective layer coated thereon, and at least one binder material fiber of the plurality may have a second protective layer coated thereon. The first and second protective layers may be the same or different. The binder material fibers can include polytetrafluoroethylene (PTFE).

Abstract: The present disclosure provides a positive electroactive material for an electrochemical cell that cycles lithium ions. The positive electroactive material includes a nickel-rich material including a plurality of solid-state particles. Each solid-state particle has a heterogeneous structure that includes a core and a shell that at least partially coats the core. The core includes a nickel-cobalt-manganese material, and the shell includes a nickel-cobalt-aluminum material. When the nickel-rich material is represented by LiNi(1-x-y-z)CoxMnyAl2O2, the nickel-cobalt-manganese material is represented by LiNi(i-x?-(y/a))Cox?Mn(y/a)O2, and the nickel-cobalt-aluminum material is represented by LiNi(i-x?-(z/b))Cox?Al(z/b)O2, where (i) 1-x-y-z>0.5, (ii) a+b=1, (iii) zx?+bx?=x, and (iv) 1-x?-(y/a)>1-x?-(z/b). In certain variations, the core and the shell define a base structure, and the heterogeneous structure further includes a buffer layer that at least partially coats the base structure.

Abstract: An electrochemical cell that includes a first electrode, a second electrode, and an electrolyte layer that is disposed between the first electrode and the second electrode is provided. The electrolyte layer includes a porous scaffold having a porosity greater than or equal to about 50 vol. % to less than or equal to about 90 vol. %, and a solution-processable solid-state electrolyte that at least partially fills the pores of the porous scaffold. The porous scaffold is defined by a plurality of fibers having an average diameter greater than or equal to about 0.01 micrometer to less than or equal to about 10 micrometers and an average length greater than or equal to about 1 micrometer to less than or equal to about 20 micrometers. The solution-processable solid-state electrolyte includes is selected from the group consisting of: sulfide-based solid-state particles, halide-based solid-state particles, hydride-based solid-state particles, and combinations thereof.

Abstract: The present disclosure provides an electrochemical cell that cycles lithium ions. The electrochemical cell includes a first electrode, a second electrode, a separator physically separating the first and second electrodes, a solid-state interlayer disposed between the separator and the first electrode, and a liquid electrolyte disposed in each of the first electrode, the second electrode, the separator, and the solid-state interlayer. The solid-state interlayer includes a plurality of solid-state electrolyte particles. The solid-state interlayer covers greater than or equal to about 85% of a total surface area of the surface of the first electrode.

Abstract: The present disclosure a gel polymer electrolyte for an electrochemical cell that cycles lithium ions. The gel polymer electrolyte includes a polymer host, a liquid electrolyte, and greater than or equal to about 0.1 wt. % to less than or equal to about 10 wt. % of a sulfolene additive. In certain variations, the gel polymer electrolyte also includes greater than or equal to about 0.1 wt. % to less than or equal to about 5 wt. % of an ethylene carbonate additive. The ethylene carbonate additive may be selected from the group consisting of: vinyl ethylene carbonate (VEC), fluoroethylene carbonate (FEC), vinylene carbonate, and combinations thereof. In each instance, the lithium electrolyte may include a first lithium salt, a second lithium salt that is distinct from the first lithium salt, and a third lithium salt that is distinct from the first lithium salt and the second lithium salt.

Abstract: The present disclosure provides an electrolyte layer for use in an electrochemical cell that cycles lithium ions. The electrolyte layer includes a porous film that defines a plurality of voids and includes a plurality of solid-state electrolyte particles and a plurality of polymeric fibrils that connect the solid-state electrolyte particles. The electrolyte layer also includes a gel polymeric electrolyte that at least partially fills the plurality of voids in the porous film. The porous film has a thickness greater than or equal to about 2 micrometers to less than or equal to about 100 micrometers, and a porosity greater than or equal to about 10 vol. % to less than or equal to about 50 vol. %. The a gel polymeric electrolyte fills greater than or equal to about 0.1% to less than or equal to about 150% of a total porosity of the porous film.

Abstract: An anode-free solid-state battery includes a cathode layer having transient anode elements and a bare current collector devoid of non-transitory anode material and configured to accept thereon the transient anode elements. The battery also includes a solid-state electrolyte layer defining voids and arranged between the current collector and the cathode layer. The battery additionally includes a gel situated within the solid-state electrolyte and cathode layers, to permeate the electrolyte voids and form a gelled solid-state electrolyte layer, coat the cathode layer, and facilitate ionic conduction of the anode elements between the cathode layer, the solid-state electrolyte layer, and the current collector. Charging the battery diffuses the anode elements from the cathode layer, via the gelled solid-state electrolyte layer, onto the current collector. Discharging the battery returns the anode elements, via the gelled solid-state electrolyte layer, to the cathode layer.

Abstract: An electrochemical cell that cycles lithium ions includes a positive electrode, a negative electrode current collector spaced apart from the positive electrode, and an ionically conductive electrolyte disposed between the positive electrode and the negative electrode current collector. The negative electrode current collector is of unitary one-piece construction and has a three-dimensional porous structure that defines an interconnected network of open pores. During charging of the electrochemical cell, lithium metal is deposited within the open pores of the negative electrode current collector.

Abstract: A negative electrode for an electrochemical cell that cycles lithium ions includes a particulate component embedded in a polymeric matrix component that comprises polytetrafluoroethylene. The particulate component includes a plurality of composite particles, with each of the composite particles having a core and a selective barrier layer disposed on a surface of the core. The core of each of the composite particles includes an electroactive negative electrode material. The selective barrier layer of each of the composite particles is formulated to prevent or inhibit electrochemical reactions from occurring between lithium stored in the electroactive negative electrode material of the core and the polytetrafluoroethylene in the polymeric matrix component.

Abstract: A gel polymer electrolyte for an electrochemical cell that cycles lithium ions comprises a polymer matrix infiltrated with a liquid electrolyte solution. The polymer matrix comprises poly(vinylidene fluoride-co-hexafluoropropylene). The liquid electrolyte solution comprises a nonaqueous organic solvent, a first lithium salt in the nonaqueous organic solvent, and a second lithium salt in the nonaqueous organic solvent. The first lithium salt comprises lithium difluoro(oxalato)borate and the second lithium salt comprises lithium bis(trifluoromethanesulfonyl)imide.

Abstract: The present disclosure provides an electrochemical cell that cycles lithium ions, where the electrochemical cell includes an electrode, a solid-state electrolyte layer, and a solid-state interlayer disposed between the electrode and the solid-state electrolyte layer. The solid-state interlayer includes a plurality of solid-state electrolyte particles. In certain instances, the solid-state interlayer includes a plurality of through-holes dispersed therewithin. The through-holes have an average diameter between about 0.05 to about 100 micrometers. The solid-state interlay covers between about 50% and about 100% of a total surface area of the electrode. In each variation, solid-state interlayer has a thickness greater than or equal to about 0.1 to less than or equal to about 8 micrometers, and the electrochemical cell may include a polymeric gel electrolyte that at least partially fills voids between solid-state electroactive particle and solid-state electrolyte particles.

Abstract: A battery system comprises N folded bipolar batteries folded in an “S”-shaped configuration. First and second folded portions of each of the N folded bipolar batteries are arranged on opposite ends of the “S”-shaped configuration. First side portions and second side portions of each of the N folded bipolar batteries are arranged between the first and second folded portions. One or more of the first folded portions on a first one of the N folded bipolar batteries are in direct electrical contact with one or more of the second folded portions on a second one of the N folded bipolar batteries. One or more of the first side portions on a third one of the N folded bipolar batteries are in direct electrical contact with one or more of the second side portions on a fourth one of the N folded bipolar batteries.

Abstract: A solid-state battery system including a graphite anode is provided. The system includes a battery cell. The battery cell includes the graphite anode, a cathode, and a solid electrolyte layer. The graphite anode includes a plurality of graphite particles, wherein the plurality of graphite particles includes a first portion of the plurality of graphite particles including a plurality of relatively high specific surface area graphite particles and a second portion of the plurality of graphite particles including a plurality of relatively low specific surface area graphite particles. The solid electrolyte layer is disposed between the graphite anode and the cathode and is operable to provide lithium-ion conduction path between the graphite anode and the cathode.

Abstract: A polymeric gel electrolyte for an electrochemical cell, such as a solid-state battery, is provided herein as well an electrochemical cell including the polymeric gel electrolyte. The polymeric gel electrolyte includes one or more lithium salts, a plasticizer component, an additive component, and a polymeric host. Examples of the plasticizer component include a carbonate, a lactone, a nitrile, a sulfone, an ether, a phosphate, and combinations thereof. The additive component includes a boron-containing additive and a carbonate-containing additive.